Package with tray enclosure

ABSTRACT

Provided is a pocket-sized container for holding a smokeless tobacco tray enclosure in an outer housing, including a front and a back. At least one locator fin is located on the bottom of the tray. At least one locator groove is located on the inside of the back. Preferably, one or more locator fins position and secure the tray within the back. Pins on the front fit into sockets in the back to secure the front and back together.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S. provisional Application No. 60/924,797, filed May 31, 2007, the entire content of which is incorporated herein by reference.

SUMMARY

Provided herein is a container adapted to hold a number of consumer items, such as smokeless tobacco products, and in particular to a pocket-size container that can be held and opened by one hand of a consumer to expose the items therein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a smokeless tobacco tray enclosure.

FIG. 2 illustrates an embodiment of a contoured tray having straight locator fins.

FIG. 3 illustrates an embodiment of a contoured tray having flared locator fins.

FIG. 4 is an exploded view of the outer housing of the smokeless tobacco tray enclosure.

DETAILED DESCRIPTION

As described herein, a pocket-size container has a sealed tray with locator fins for positioning and securing the tray within an outer housing.

In a preferred embodiment, the pocket-size container is capable of being held in one hand of a consumer and opened by a finger or thumb of that hand. The container, which is preferably formed of about three to about six pieces, preferably contains a tray containing consumer items that is sealed with a membrane. An openable window on the membrane situated behind an access opening of the container facilitates access to the contained items. In a preferred embodiment, the container includes a tray having locator fins for positioning and holding the tray within a back portion of the outer housing.

Preferably, the tray has an inner cavity, capable of holding a product, such as smokeless tobacco pouches, and an outside surface. In an embodiment, at least one locator fin is located on one end of the outside surface of the tray for positioning and holding the tray within the outer housing. Preferably, no adhesives or other substances are needed to secure the tray within the outer housing, but such adhesives may be used if desired.

In an embodiment, the inner cavity of the contoured tray is sealed by a membrane. Preferably, the tray is hermetically sealed to prevent moisture from escaping from the enclosed product. In an embodiment, the membrane may cover just the inner cavity. In another embodiment, the membrane covers the entire tray, while still allowing the locator fin to function as a device to position and hold the tray within the outer housing.

Preferably, the seal is formed by a poly-laminated membrane. Also preferably, the poly-laminated membrane includes a pull tab that is engaged to break the seal of the membrane and provide access to the contents of the inner cavity of the tray.

In a preferred embodiment, the outer housing includes a back and a front. Preferably, the front includes a lid that opens to reveal the pull tab of the membrane. In an embodiment, the lid slides open and remains within the footprint of the container. In another embodiment, the lid is hingedly connected to the front. Preferably, the front is designed to fit over the tray.

Also preferably, the back has an inner cavity and an outside surface. In an embodiment, at least one locator groove is located on one end of the inner cavity of the back. Preferably, the location of the locator groove corresponds to the location of the at least one locator fin located on one end of the tray. In an embodiment, the locator groove can be located at any location within the inner cavity so long as the groove corresponds to the location of the locator fin on the tray.

In use, the tray is guided into the back by the locator fins so that the locator fins fit into the locator grooves. The fins and grooves are preferably held together by friction. In another embodiment, the fins may have an enlarged portion and the grooves may expand to receive the enlarged portion such that the tray and back snap together to hold the tray securely within the back portion of the outer housing.

In an embodiment, the front includes at least one pin extending downward from the bottom of the front portion of the outer housing. Also preferably, the back includes at least one pin hole corresponding to each of the pins in the front. To form the outer housing, the pins on the front are lined up with the sockets on the back so that the front and back are secured together to form the outer housing. Preferably, the outer housing fits securely around the sealed tray.

Also provided is a method for packaging a smokeless tobacco product. The method includes filling a contoured, tray with a smokeless tobacco product and hermetically sealing the tray with a poly-laminated membrane. Preferably, the tray has locator fins on the bottom that are lined up with locator grooves inside the back portion of the outer housing. The tray is then fitted into the back using the locator fins as guides, and secured within the back portion. Preferably, the front is then positioned over the back so as to line up pins in the front with sockets in the back. The pins are inserted into the pin holes to secure the front to the back to form a pocket-size container.

As seen in FIG. 1, a pocket-size container 10 for smokeless tobacco products 50 includes an outer housing 12 having a front 32 that is designed to fit over and around the tray 14 and engage with the back 30 to form the outer housing 12. Preferably, the container 10 includes a lid 34, which allows access to the unused product stored in the tray 14 and a receptacle for storing spent product as disclosed in U.S. provisional Application No. 60/924,714, filed on May 29, 2007, the entire content of which is incorporated herein by reference. In a preferred embodiment, the receptacle is located adjacent a first end 38 of the container 10 and is accessible via a second lid in the back 30. In another embodiment, the receptacle may be in a central location on the container or accessible via a second lid in the front. Most preferably, locator fins 24 hold the tray 14 securely within the back 30 of the outer housing 12.

In an embodiment, the pocket-size container 10 is an injection molded or thermally formed plastic tray. Suitable plastics include, without limitation, polypropylene, polyethylene, polystyrene, nylon, polysulfone, polyester, polyurethane, and combinations thereof. Because some plastics absorb flavors, the preferred plastic is polypropylene if the enclosed product includes flavors.

In other embodiments, the pocket-size container 10 is cast of metal or formed from wood. Suitable metals, include without limitation aluminum.

In an embodiment, the pocket-size container 10 is about 1 inch to about 3 inches wide and 3 inches to about 5 inches long. In a preferred embodiment, the pocket-size container 10 fits in the palm of an adult user's hand or in a pocket. Most preferably, the size of the pocket-size container 10 is determined based on the amount of product 50 to be enclosed. In an embodiment, the container is about 30 mm to about 60 mm wide, about 70 mm to about 100 mm long, and about 15 mm to about 40 mm deep.

Also preferably, the tray 14 is contoured to hold a smokeless tobacco product. In an embodiment, the tray 14 is shaped to have an outside 16 and an inner cavity 18 that is capable of holding a product 50 within the tray 14. Preferably, the enclosed product 50 is a smokeless tobacco product such as snus (pouched tobacco products).

The tray 14 may be any shape including rectangular, square, oval, round, octagonal, and other shapes. Preferably, the tray 14 is sized and configured to fit within the back portion 30 of the outer housing 12. Most preferably, the tray 14 has curved sides and bottom to maximize the available volume for product storage. Likewise, the outer housing may also have curved sides, tops, and bottoms to accommodate the shape of the tray 14.

Preferably, the tray 14 has a first end 20 and a second end 22. At least one locator fin 24 is located on either the first end 20 or the second end 22 of the outside 16 of the tray 14. Most preferably two locator fins 24 are located on one end of the outside surface 16 of the tray 14. However, in other embodiments, the locator fins 24 may be located at any point along the outside surface 16 of the tray 14.

In a preferred embodiment, the locator fins 24 correspond to locator grooves 42 located on the inside of the back 30 so that the locator fins 24 fit within the grooves 42 to hold and secure the tray 14 within the back portion 30.

In an embodiment, the locator fins 24 snap into the locator grooves 42. In another embodiment, friction holds the locator fins 24 within the locator grooves 42.

Preferably, the locator fins 24 also prevent nesting of trays 14 that are stacked together prior to assembly of the pocket-sized container 10.

In a preferred embodiment, the locator fins 24 are straight, as seen in FIG. 2, and slide into the locator grooves 42. In another embodiment, as seen in FIGS. 1 and 3, the locator fins 24 are flared or curved, and are preferably inserted into the locator grooves 42 by pushing vertically down. The locator fins 24 may also be formed in other suitable shapes that allow the locator fins 24 to lock in place within locator grooves 42. In a preferred embodiment, the corresponding locator grooves 42 are sized and shaped to securely accommodate the shape of the locator fins 24. Preferably, the locator fins are about 1 mm to about 3 mm long.

Preferably, a membrane 26 seals the tobacco product within the tray 14. In a preferred embodiment, the membrane 26 provides a hermetic seal that retains the moisture of the product 50, as seen in FIGS. 2 and 3, within the tray 14.

In a preferred embodiment, the membrane 26 is a poly-laminated foil membrane when a hermetic seal is required. In another embodiment, the membrane is made of foil.

In a preferred embodiment, the membrane 26 has a pull tab 28 that is pulled by the consumer to break the seal and expose the smokeless tobacco product 50 held within the tray 14. In an embodiment, only one portion of the membrane 26 is opened and removed when the tab 28 is pulled. If desired, a section of material can be torn from the membrane 26 when the tab 28 is pulled to form an access opening into the tray for removal of product. The membrane can be pre-scored so that when the tab 28 is pulled, a uniform opening is formed.

In a preferred embodiment, the membrane 26 covers only the top portion of the tray 14. In another embodiment, the membrane 26 may cover the tray 14 so long as the membrane 26 does not interfere with the positioning and securing functions of the locator fins 24.

Preferably, the front 32 includes a lid 34 on the top surface 52. In an embodiment, the lid 34 slides open. In another embodiment, the lid 34 is hinged. The lid 34 may be formed in the middle of the front 32 or to one side.

In an embodiment, the lid 34 is secured by a securement mechanism which is yieldable to manual pressure.

Preferably, the lid 34 covers an opening 55 that is sized and configured to allow for easy removal of the product 50 from the inner cavity 18 of the tray 14 once at least a portion of the membrane 26 has been removed.

In a preferred embodiment, the lid 34 in the front 32 is positioned so that the lid 34 remains within the footprint of the container 10 and opens to reveal the pull tab 28 of the membrane 26. Therefore, the tray is preferably sealed or positioned within the outer housing 12 so that the pull tab 28 will align with the opening 55, created when the lid 34 is opened, once the locator fins 24 and locator grooves 42 are aligned and locked into position to secure the inner tray 14 within the back 30.

In lieu of a sealed tray, the product could simply be placed directly into the compartment formed by the outer housing or in a sealed bag having an openable and/or resealable window.

In a preferred embodiment, the front 32 includes rearwardly projecting pins 45 located on a bottom rim 62 that are receivable in respective sockets 44 disposed in the upper rim 65 of the back 30 thereby securing the front and back portions together. The pins 45 and sockets 44 are located so that the front 32 can be attached to the back 30 in only one position.

In an embodiment, as shown in FIG. 1, to close the outer housing 12 around the tray 14, the pin 45 is inserted into the socket 44 to hold the front 32 and the back 30 together. Preferably, no adhesives are needed to secure the pin 45 within the socket 44. However, adhesives may be used if desired.

In an embodiment, if the top rim 70 of the tray 14 interferes with the positioning of the pin 45 in the pin hole 44, slits and/or holes 46 may be cut in the rim 70 of the tray 14.

As seen in FIG. 4, the front portion 32 may be secured to the back portion 30 by a ball 80 and socket 85 type mechanism. In other embodiments, a friction fit connection secures the front to the back.

Also provided is a method of packaging a smokeless tobacco product. Preferably, the method includes filling a tray with a smokeless tobacco product. A poly-laminated membrane is then used to hermetically seal the smokeless tobacco product within the tray.

Next, locator fins located on the bottom of the tray are lined up with the locator grooves located inside of the bottom of the back portion of the outer housing. The tray is inserted into the back portion so that the locator fins rest and are secured within the corresponding locator grooves so that the tray is held in place within the back.

Preferably, the front is then positioned so that the pins in the bottom of the front are aligned with the sockets in the top rim of the back. The pins are then inserted in the sockets to hold the front portion together with the back portion.

In use, a consumer grips the back of the container 10 in the palm of his/her hand, while another digit of the consumer's hand, preferably the thumb, and slides the lid 34 on the front of the container 10. As the lid 34, when fully opened, remains within the footprint of the container 10, it can be easily opened without abutting the consumer's palm as could be the case if the lid were so long that the bottom portion thereof traveled outside of the container's footprint.

The hermetically sealed tray keeps the items in a fresh state until ready for use, and can be conveniently opened, and optionally resealed.

In an embodiment, the container 10 is enclosed in a shrink-wrap enclosure which includes a tear strip along one side for opening the shrink wrap.

However, the particular dimensions and proportions of the container are not critical. The proportions are preferably selected to provide a container which is suitably sized to accommodate the particular items to be packaged therein. Thus, the actual container could be more elongated than shown in the drawings, or the container could be more nearly square, i.e., shorter than shown in the drawings. Preferably, however, the container is sized so it can be conveniently carried in a pocket, and held and opened by one hand of a consumer.

The items can be arranged in various ways. For example, the products could be arranged with the items overlapped or staggered relative to one another. Of course, if the products are small enough, they could be randomly placed in the tray, bag, or loosely held inside the outer housing without a tray or bag.

The container can be used for a variety of products. One specific product for which the container can be used is smokeless pouched tobacco. Such tobacco is provided in packets, sometimes known as “snus” and comprise individual packets of tobacco material.

From the foregoing, it will be appreciated that an inexpensive pocket-size container capable of holding multiple items, and capable of being held and opened in one hand of a consumer is provided.

It should be understood that the foregoing description is of the preferred embodiments, and is, therefore, merely representative of the article and methods of manufacturing the same. It can be appreciated that variations and modifications of the different embodiments in light of the above teachings will be readily apparent to those skilled in the art. Accordingly, exemplary embodiments, as well as alternative embodiments, may be made without departing from the spirit and scope of the articles and methods as set forth in the attached claims. 

1. A pocket-size hand-held container for containing a supply of consumer items comprising: an outer housing including a front portion and a back portion; a lid attached to the front portion, which when opened reveals an access opening in the outer housing; a tray received within the outer housing, the tray including a storage compartment formed by a bottom wall and sidewalls of the tray; and at least one locator fin on an outside surface of said tray; and at least one locator groove on an inside surface of said back portion; wherein said at least one locator fin fits within said at least one locator groove to position and hold said tray within said outer housing.
 2. The pocket-size hand-held container of claim 1, wherein said lid is slideable linearly in the longitudinal direction between closed and open positions and wherein in its fully closed position, the first lid overlying the access opening, and in its fully open position, the first lid exposing the access opening and situated within the footprint of the container.
 3. The pocket-size hand-held container of claim 1, wherein said lid is hingedly connected to said front portion.
 4. The pocket-size hand-held container of claim 1, wherein said locator fin is located on an end of said outside surface of said tray
 5. The pocket-size hand-held container of claim 1, wherein the tray is hermetically sealed by a membrane.
 6. The pocket-size hand-held container of claim 5, wherein said membrane includes a manually openable window disposed beneath the access opening.
 7. The pocket-size hand-held container of claim 6, wherein the openable window is resealable.
 8. The pocket-size hand-held container of claim 5, wherein said membrane is a poly-laminated membrane.
 9. The pocket-size hand-held container of claim 1, wherein said tray contains a plurality of smokeless tobacco pouch products.
 10. The pocket-size hand-held container of claim 1, wherein said container is about 30 mm to about 60 mm wide, about 70 mm to about 100 mm long, and about 15 mm to about 40 mm deep.
 11. The pocket-size hand-held container of claim 1, wherein said front portion includes at least one pin and said back portion includes at least one socket receiving said at least one pin so as to secure said front portion to said back portion.
 12. The pocket-size hand-held container of claim 1, wherein said at least one locator fin comprises two fins, each fin located closer to the sidewall of the tray than the middle of the tray.
 13. The pocket-size hand-held container of claim 1, wherein said tray is of rigid plastic.
 14. The pocket-size hand-held container of claim 1, wherein said tray is injection molded.
 15. The pocket-size hand-held container of claim 14, wherein said tray is injection molded of a material selected from the group consisting of polypropylene, polyethylene, polystyrene, nylon, polysulfone, polyester, polyurethane, and combinations thereof
 16. The pocket-size hand-held container of claim 11, wherein said front portion includes pins on opposite sides thereof and said tray is shaped to fit around said pins of the front portion to avoid interfering with the assembly of the outer housing.
 17. The pocket-size hand-held container of claim 1, wherein said locator fin includes a portion which is straight and/or flared.
 18. A method of packaging smokeless tobacco products comprising: filling a tray with smokeless tobacco products; hermetically sealing said tray with a membrane; lining up a locator fin on said tray with a locator groove on a back portion; fitting said tray into said back portion; positioning a front portion over said back portion so as to line up pins in the front portion with sockets in the back portion; and inserting said pins in the front portion into the sockets in the back portion to form a pocket-sized container. 